Flat wire winding and multiphase electric machine

Abstract

A flat wire wave winding and a multiphase motor, wherein the flat wire wave winding comprises a first shaped wire, a second shaped wire, a third shaped wire and a fourth shaped wire. The first shaped wire, the second shaped wire, the third shaped wire and the fourth shaped wire respectively comprise a plurality of straight wire portions and a plurality of bridge portions for connecting two adjacent straight wire portions. The span of two adjacent straight wire portions of the first shaped wire and the third shaped wire is sequentially maintained as a first span and a second span in turn, and the span of two adjacent straight wire portions of the second shaped wire and the fourth shaped wire is sequentially maintained as the second span and the first span in turn.

Description

Technical Field

[0001] This invention relates to a flat wire winding and a multiphase motor, and more particularly to a flat wire winding for motors and a multiphase motor. Background Technology

[0002] New energy vehicles primarily use electric motors as their power source. An electric motor consists of a stator and a rotor, generating power through the electromagnetic effect between them. Existing stator flat wire windings are mainly divided into hairpin type and straight wire type (i-pin). Both require extensive bending and welding of the wires. Damage during manufacturing can affect the conductivity of the windings and the overall efficiency of the motor. Summary of the Invention

[0003] This invention provides a flat wire wave winding and its forming method to solve the above-mentioned problems.

[0004] This invention discloses a flat wire winding, comprising a first shaped conductor, a second shaped conductor, a third shaped conductor, and a fourth shaped conductor. Each of the first, second, third, and fourth shaped conductors includes a plurality of straight conductor portions and a plurality of bridging portions for connecting two adjacent straight conductor portions. The span between two adjacent straight conductor portions of the first and third shaped conductors alternately varies between a first span and a second span. Similarly, the span between two adjacent straight conductor portions of the second and fourth shaped conductors alternates between a second span and a first span.

[0005] This invention also discloses a multiphase motor, comprising: a stator having a plurality of stator slots, wherein one side of the stator is a lead-out side and the other side is a non-lead-out side; a rotor having a plurality of pole pairs; and a flat wire winding disposed in the stator. The flat wire winding comprises: a first shaped conductor, a second shaped conductor, a third shaped conductor, and a fourth shaped conductor. The first, second, third, and fourth shaped conductors each comprise a plurality of straight conductor portions sequentially occupying stator slots and a plurality of bridging portions for connecting two adjacent straight conductor portions. The plurality of straight conductor portions include a lead-out section conductor, a connecting section conductor, and a plurality of straight section conductors. The lead-out section conductor includes a lead-out end, and the connecting section conductor includes a connecting end. The lead-out end and the connecting end are located on the lead-out side. Some of the plurality of bridging portions are located on the lead-out side, and some are located on the non-lead-out side. The spans of two adjacent straight conductor sections of the first and third shaped conductors alternately change between a first span and a second span. Furthermore, the spans of two adjacent straight conductor sections of the second and fourth shaped conductors alternately change between a second span and a first span. Attached Figure Description

[0006] Figure 1 This is a schematic diagram of the flat wire wave winding according to an embodiment of the present invention.

[0007] Figure 2A This is a schematic diagram of the unfolded flat wire wave winding of the present invention.

[0008] Figure 2B This is a top view of the flat wire wave winding of the present invention, viewed from the stator side.

[0009] Figure 3 This is a schematic diagram of the shape of the first formed conductor of the flat wire wave winding according to an embodiment of the present invention.

[0010] Figure 4 This is a schematic diagram of the structure of the first shaped conductor in the stator according to an embodiment of the present invention.

[0011] Figure 5 This is a top view of the structure of the first shaped conductor in the stator according to an embodiment of the present invention.

[0012] Figure 6 This is a schematic diagram of the second shaped conductor of the flat wire winding according to an embodiment of the present invention.

[0013] Figure 7 This is a schematic diagram of the structure of the second shaped conductor in the stator according to an embodiment of the present invention.

[0014] Figure 8 This is a schematic diagram of the third shaped conductor shape of the flat wire winding according to an embodiment of the present invention.

[0015] Figure 9 This is a schematic diagram of the structure of the third molded conductor in the stator according to an embodiment of the present invention.

[0016] Figure 10 This is a schematic diagram of the fourth shaped conductor of the flat wire winding according to an embodiment of the present invention.

[0017] Figure 11 This is a schematic diagram of the structure of the fourth shaped conductor in the stator according to an embodiment of the present invention.

[0018] Figure 12 This is a schematic diagram of the unfolded first pair of shaped wires according to an embodiment of the present invention.

[0019] Figure 13 This is a schematic diagram of the unfolded second pair of shaped wires according to an embodiment of the present invention.

[0020] Figure 14A This is a schematic diagram of the first coil in an embodiment of the present invention.

[0021] Figure 14B This is a schematic diagram of the structure of the first coil in the stator according to an embodiment of the present invention.

[0022] Figure 15 This is a schematic diagram of the second coil in an embodiment of the present invention.

[0023] Figure 16 This is a schematic diagram of the winding structure of the flat wire wave winding in the stator according to an embodiment of the present invention.

[0024] Figure 17 This is a schematic diagram of the winding structure of the flat wire wave winding in the stator according to another embodiment of the present invention.

[0025] Figure 18A This is a schematic diagram of the stator and stator slots according to an embodiment of the present invention.

[0026] Figure 18B This is a schematic diagram showing the position of the conductor layer in a stator slot according to an embodiment of the present invention.

[0027] Figure label: 1: Stator 10: Flat wire wave-wound coil 12: Stator slot 20: Ejection side 30, 60, 80, 100: First-formed conductor 120: First pair of formed conductors 130: Second pair of shaped conductors 301, 601, 801, 1001: Lead-out conductors 316, 616, 816, 1016: Connecting section conductors 302~315, 602~615, 802~815, 1002~1015: Straight-line traverse segments 401~415, 701~715, 901~915, 1101~1115: Bridging section 350, 650, 850, 1050: Connecting end 360, 660, 860, 1060: Output pins L1~L8: Location of conductor layers U1, U2, U3, U4: Coils Detailed Implementation

[0028] Figure 18A and Figure 18B Schematic diagrams of the stator, stator slots, and conductor layer according to embodiments of the present invention are shown respectively. Figure 18A As shown, in this embodiment of the invention, the stator 1 includes a plurality of stator slots 12, the open ends of which face the rotor (not shown in the figure). Figure 18B As shown, each stator slot 12 is defined with a plurality of conductor layer positions so that the flat wire wave winding of the present invention can be placed therein. Figure 18BAlthough the example uses eight conductor layers L1 to L8, the present invention is applicable to any embodiment with an even number of conductor layers and is not limited to eight layers.

[0029] Please see Figure 1 , Figure 2A and Figure 2B . Figure 1 This is a schematic diagram of the flat wire wave winding 10 according to an embodiment of the present invention. Figure 2A A schematic diagram of the unfolded structure of the flat-wave winding 10, and Figure 2B This is a top view of the flat wire wave winding 10 from one side of the stator 1. As shown, the flat wire wave winding 10 of the present invention is composed of a plurality of integrally formed shaped conductors, each shaped conductor including a plurality of straight conductor portions and a plurality of bridging portions. Also shown, on a tooling device, the flat wire wave winding 10 of the present invention can be bent into the required shape and then pushed into the corresponding stator slot 12 and conductor layer position through the open end of the stator slot 12. In one embodiment, the leads of the flat wire wave winding 10 of the present invention are concentrated on one lead-out side 20 of the stator. Furthermore, the flat wire wave winding 10 of the present invention does not limit the number of parallel branches per phase current; the designer can design the coil of the flat wire wave winding 10 as a stator winding with 1, 2, or 4 branches connected in parallel according to actual needs.

[0030] In one embodiment, the flat wire wave winding 10 of the present invention can be applied to a multiphase motor. The multiphase motor has (2*n) stator slots, each stator slot defines (2*k) conductor layer positions, and the rotor has p pole pairs, where (2*k) is an even number not less than 4. Based on the above assumptions, the pole pitch D of the multiphase motor in this embodiment of the present invention can be expressed as: D = (2*n) / (2*p); furthermore, the number of poles per phase can be expressed as: (D / number of phases). For example, suppose a three-phase motor contains 48 stator slots (n=24), each stator slot defines 8 conductor layer positions (k=4), and the rotor contains 4 pole pairs (p=4). According to this embodiment, the pole pitch D of the three-phase motor is 6, and the number of poles per phase is 2. To clearly illustrate the spirit of the present invention, the following description of the flat wire wave winding, unless expressed algebraically, is based on this 48-stator-slot three-phase motor embodiment.

[0031] like Figure 1 and Figure 2AAs shown, the flat wire winding 10 of this embodiment includes a plurality of coils, which sequentially occupy the stator slot 12 and the conductor layer position. In one embodiment, each coil consists of at least one shaped conductor. The shaped conductor includes a plurality of straight conductor portions and a plurality of bridging portions. The straight conductor portion includes a lead-out section conductor, a connecting section conductor, and a plurality of straight conductor segments. Furthermore, the lead-out section conductor end includes a lead-out end, and the connecting section conductor end includes a connecting end; wherein the lead-out end and the connecting end are located on the lead-out side 20 of the stator 1. The bridging portions are used to connect two adjacent straight conductors. The bridging portions can be divided into lead-out side bridging portions on the stator lead-out side 20 and non-lead-out side bridging portions not on the stator lead-out side 20.

[0032] In one embodiment, the number of straight conductor portions (including lead-out conductors, connecting conductors, and straight conductor segments) and bridging portions of a formed conductor can be designed to be determined by the number of stator slots and the number of motor phases. For example, in a three-phase motor with 48 stator slots, each formed conductor can be designed to include 16 straight conductor portions (i.e., 16 = 48 / 3) and 15 bridging portions (i.e., 15 = 16-1). Although the present invention does not limit the number of straight conductor portions and bridging portions, in practical design, at least four straight conductor portions and three or more bridging portions can achieve better results.

[0033] Figure 16 and Figure 17 This diagram illustrates two possible winding structure configurations of the flat wire wave winding 10 in the stator according to the present invention. As shown in the figure, in one embodiment, the stator 1 may include 48 stator slots numbered sequentially from 1# to 48#, and each stator slot defines 8 conductor layer positions L1 to L8. L1 is the outermost conductor layer position, and L8 is the innermost conductor layer position near the stator slot opening.

[0034] The flat wire wave winding 10 of the present invention is composed of a plurality of coils. As shown in the figure, in one embodiment, the flat wire wave winding 10 of the present invention includes a plurality of first coils U1, a plurality of second coils U2, a plurality of third coils U3, and a plurality of fourth coils U4. Each coil includes at least one shaped conductor, according to the winding rules of the flat wire wave winding 10 of the present invention (…). Figure 16 or Figure 17 The stator slots and conductor layers are filled. Furthermore, at least one first coil U1, at least one second coil U2, at least one third coil U3, and at least one fourth coil U4 constitute a phase winding. Detailed winding rules for the flat-wave winding 10 will be discussed in subsequent paragraphs.

[0035] The flat wire wave winding 10 of the present invention may comprise a plurality of shaped conductors of different shapes. In one embodiment, the flat wire wave winding 10 of the present invention is composed of four different shaped conductors, as shown below. Figure 3 , Figure 6 , Figure 8 and Figure 10 As shown in the figure, taking a three-phase motor with 48 stator slots as an example, each shape of the formed conductor may include 16 straight conductors (48 stator slots / 3 phases) and 15 bridging portions, but the present invention is not limited thereto. The following description uses a three-phase motor with 48 stator slots as an example.

[0036] Please see Figure 3 , Figure 4 and Figure 5 . Figure 3 This is a schematic diagram of the shape of the first molded conductor 30 of the present invention. Figure 4 This is a schematic diagram of the structure of the first shaped conductor 30 in the stator. Figure 5 Based on the first formed conductor 30 Figure 16 The top view of the winding rules in the stator structure.

[0037] like Figure 3 As shown, the first shaped conductor 30 includes a plurality of straight conductor portions 301-316 and a plurality of bridging portions 401-415. Each straight conductor portion includes a lead-out conductor 301, a connecting conductor 316, and a plurality of straight conductor segments 302-315. Figure 5 As shown, the straight conductor portions 301 to 316 of the first formed conductor 30 occupy specific stator slots and specific conductor layer positions respectively according to a winding rule of the present invention. Furthermore, the lead-out section conductor 301 includes a lead-out end 360, and the connecting section conductor 316 includes a connecting end 350. The lead-out end 360 and the connecting end 350 are located on the lead-out side of the stator. Bridging portions 401 to 415 respectively connect adjacent straight conductors. For example, bridging portion 401 connects lead-out section conductor 301 and straight section conductor 302, bridging portion 402 connects straight section conductors 302 and 303, and bridging portion 415 connects straight section conductor 315 and connecting section conductor 316, and so on. Bridging portions 401, 403, 405, 407, 409, 411, 413, and 415 are located on the non-lead-out side of the stator, while bridging portions 402, 404, 406, 408, 410, 412, and 414 are located on the lead-out side of the stator. The distance between two adjacent straight segments of the first shaped conductor 30 can be one of a first span, a second span, or a third span; this will be further explained in subsequent paragraphs. According to one embodiment, refer to... Figure 3 A first shaped conductor 30 may include 16 straight conductors (48 stator slots / 3 phases) and 15 bridging sections, but the present invention is not limited thereto.

[0038] Please see Figure 6 and Figure 7 . Figure 6 This is a schematic diagram of the shape of the second shaped conductor 60. Figure 7 This is a schematic diagram of the structure of the second shaped conductor 60 in the stator. (See diagram below.) Figure 6 As shown, the second shaped conductor 60 includes a plurality of straight conductor portions 601-616 and a plurality of bridging portions 701-715. Each straight conductor portion includes a lead-out section conductor 601, a connecting section conductor 616, and a plurality of straight section conductors 602-615; these straight conductor portions occupy specific stator slots and specific conductor layer positions according to a winding rule of the present invention. Furthermore, the lead-out section conductor 601 includes a lead-out end 660, and the connecting section conductor 616 includes a connecting end 650; the lead-out end 660 and the connecting end 650 are located on a lead-out side of the stator. Bridging portions 701-715 respectively connect adjacent straight conductors. For example, bridging portion 701 connects the lead-out section conductor 601 and the straight section conductor 602, bridging portion 702 connects the straight section conductors 602 and 603, and bridging portion 715 connects the straight section conductor 615 and the connecting section conductor 616. Among them, bridging portions 701, 703, 705, 707, 709, 711, 713, and 715 are located on the non-lead-out side of the stator, while bridging portions 702, 704, 706, 708, 710, 712, and 714 are located on the lead-out side of the stator. The distance between two adjacent straight segments of the second shaped conductor 60 can be one of a first span, a second span, or a fourth span; this will be further explained in subsequent paragraphs. According to one embodiment, refer to... Figure 6 Each second shaped conductor 60 may include 16 straight conductors (48 stator slots / 3 phases) and 15 bridging sections, but the invention is not limited thereto.

[0039] Please see Figure 8 and Figure 9 . Figure 8 This is a schematic diagram of the shape of the third shaped conductor 80. Figure 9 This is a schematic diagram of the third-shaped conductor 80 in the stator. The third-shaped conductor 80 and... Figure 3 The first shaped conductor 30 shown has a similar structure, but the bending direction of the connecting end is different. For example... Figure 8As shown, the third formed conductor 80 includes a plurality of straight conductor portions 801-816 and a plurality of bridging portions 901-915. Each straight conductor portion includes a lead-out section conductor 801, a connecting section conductor 816, and a plurality of straight section conductors 802-815; these straight conductor portions occupy specific stator slots and specific conductor layer positions according to a winding rule of the present invention. Furthermore, the lead-out section conductor 801 includes a lead-out end 860, and the connecting section conductor 816 includes a connecting end 850; the lead-out end 860 and the connecting end 850 are located on a lead-out side of the stator. Bridging portions 901-915 respectively connect adjacent straight conductors. For example, bridging portion 901 connects lead-out section conductor 801 and straight section conductor 802, bridging portion 902 connects straight section conductors 802 and 803, and bridging portion 915 connects straight section conductor 815 and connecting section conductor 816. Among them, bridging portions 901, 903, 905, 907, 909, 911, 913, and 915 are located on the non-lead-out side of the stator, while bridging portions 902, 904, 906, 908, 910, 912, and 914 are located on the lead-out side of the stator. The distance between two adjacent straight segments of the third shaped conductor 80 can be one of a first span, a second span, or a third span; this will be further explained in subsequent paragraphs. According to one embodiment, refer to... Figure 8 Each third-shaped conductor 80 may contain 16 straight conductors (48 stator slots / 3 phases) and 15 bridging sections, but the invention is not limited thereto.

[0040] Please see Figure 10 and Figure 11 . Figure 10 This is a schematic diagram of the shape of the fourth shaped conductor 100. Figure 11 This is a schematic diagram of the fourth shaped conductor 100 in the stator. The fourth shaped conductor 100 and... Figure 6 The second shaped conductor 60 shown has a similar structure, but the bending direction of the connecting end is different. For example... Figure 10As shown, the fourth shaped conductor 100 includes a plurality of straight conductor portions 1001-1016 and a plurality of bridging portions 1101-1115. Each straight conductor portion includes a lead-out section conductor 1001, a connecting section conductor 1016, and a plurality of straight section conductors 1002-1015; these straight conductor portions occupy specific stator slots and specific conductor layer positions according to a winding rule of the present invention. Furthermore, the lead-out section conductor 1001 includes a lead-out end 1060, and the connecting section conductor 1016 includes a connecting end 1050; the lead-out end 1060 and the connecting end 1050 are located on a lead-out side of the stator. The bridging portions 1101-1115 respectively connect adjacent straight conductors. For example, bridging portion 1101 connects lead-out section conductor 1001 and straight section conductor 1002, bridging portion 1102 connects straight section conductors 1002 and 1003, and bridging portion 1115 connects straight section conductor 1015 and connecting section conductor 1016. Bridging portions 1101, 1103, 1105, 1107, 1109, 1111, 1113, and 1115 are located on the non-lead-out side of the stator, while bridging portions 1102, 1104, 1106, 1108, 1110, 1112, and 1114 are located on the lead-out side of the stator. The distance between two adjacent straight section portions of the fourth shaped conductor 100 can be one of a first span, a second span, or a fourth span; this will be further explained in subsequent paragraphs. According to one embodiment, refer to... Figure 10 Each fourth shaped conductor 100 may include 16 straight conductors (48 stator slots / 3 phases) and 15 bridging sections, but the present invention is not limited thereto.

[0041] In one embodiment, the first shaped conductor 30 and the third shaped conductor 80 have approximately the same shape but opposite turning directions at their connection ends. For example... Figure 3 and Figure 8 As shown, the connecting end 350 of the first molded conductor 30 is bent in the opposite direction to the lead-out end 360, while the connecting end 850 of the third molded conductor 80 is bent in the direction of the lead-out end 860. Similarly, the second molded conductor 60 and the fourth molded conductor 100 have roughly the same shape, but the bending directions of the connecting end 350 and the lead-out end 360 are opposite. Figure 6 and Figure 10 As shown, the connecting end 650 of the second shaped conductor 60 is bent in the opposite direction to the lead-out end 660, while the connecting end 1050 of the fourth shaped conductor 100 is bent in the direction of the lead-out end 1060.

[0042] As described above, the bridging portion of the shaped conductor is used to connect two adjacent straight conductor portions; wherein, the middle bend of the bridging portion is maintained approximately at the angle bisector of the two adjacent straight conductor portions. In one embodiment, the bend of the bridging portion of the shaped conductor of the present invention can be further varied in order to make more efficient use of the space for winding on both sides of the stator.

[0043] Specifically, assume a shaped conductor contains J bridging portions. As mentioned above, J can be defined as: J = (number of stator slots / number of motor phases) - 1; and the number of stator slots is assumed to be 2*n. In one embodiment, the bending of the bridging portions of the first shaped conductor 30 and the second shaped conductor 60 can vary according to the following rules: (1) On the lead-out side, the bend of the central bridging section (i.e. the (J+1) / 2nd bridging section) can be adjusted to be offset by a first arc Q1 in the direction of the lead-out section conductor, where the first arc Q1 is: pi / (2*n); (2) On the non-lead side, the bends of the first two consecutive non-lead side bridging sections near the central bridging section (i.e. the [(J+1) / 2]-1 and [(J+1) / 2]-3 bridging sections) can be adjusted to be offset by a second arc Q2 in the direction of the connecting section conductor, where the second arc Q2 is: Q2 = pi / n; (3) Except for the above changes, the bends of the remaining bridging parts are all kept at the angle bisectors of the two adjacent straight line segments.

[0044] Taking the first formed conductor 30 as an example, please refer to... Figure 3 The first shaped conductor 30 comprises 15 bridging sections, wherein the bends of bridging sections 401–406 and 409–415 are approximately maintained at the angle bisectors of two adjacent straight segments. Furthermore, the bend of the central bridging section 408 (i.e., the 8th bridging section) on the lead-out side is adjusted to be offset by a first arc Q1 = pi / (2*n) towards the lead-out section conductor 301; while the bends of the two consecutive non-lead-out end bridging sections 407 and 405 (i.e., the 7th and 5th bridging sections) before the central bridging section 408 are adjusted to be offset by a second arc Q2 = pi / n towards the connecting section conductor 316.

[0045] In another embodiment, the bending of the bridging portion of the third molded conductor 80 and the fourth molded conductor 100 can be varied as follows: (1) On the lead-out side, the bend of the central bridging section (i.e. the (J+1) / 2nd bridging section) can be adjusted to be offset by a first arc Q1 in the direction of the lead-out section conductor, where the first arc Q1 is: Q1=pi / (2*n); (2) On the lead-out side, the bend of the next lead-out side bridging part (i.e. the [(J+1) / 2]+2nd bridging part) of the central bridging part can be adjusted to be offset by a second arc Q2 in the direction of the lead-out section conductor, where the second arc Q2 is: Q2=pi / n; (3) On the non-lead side, the bend of the previous non-lead side end bridging part (i.e. the [ (J+1) / 2]-1 bridging part) near the central bridging part can be adjusted to be offset by a second arc Q2 in the direction of the connecting section conductor, where the second arc Q2 is: Q2= pi / n; (4) Except for the above changes, the bends of the remaining bridging parts are all kept at the angle bisectors of the two adjacent straight line segments.

[0046] Taking the third-shaped conductor 80 as an example, please refer to... Figure 8 The third-shaped conductor 80 comprises 15 bridging sections, wherein the bends of bridging sections 901–906, 909, and 911–915 are approximately maintained at the angle bisectors of two adjacent straight segments. Furthermore, the bend of the central bridging section 908 (i.e., the 8th bridging section) on the lead-out side is adjusted to be offset by a first arc Q1 = pi / (2*n) towards the lead-out section conductor 801; the bend of the next lead-out side bridging section 910 (i.e., the 10th bridging section) on the central bridging section 908 is adjusted to be offset by a second arc Q2 = pi / n towards the lead-out section conductor 801; and the bend of the bridging section 907 (i.e., the 7th bridging section) on a non-lead-out end near the central bridging section 908 is adjusted to be offset by a second arc Q2 = pi / n towards the connecting section conductor 816.

[0047] The flat wire wave winding 10 of this invention is composed of a plurality of shaped conductors. In the manufacturing process, the plurality of shaped conductors are stacked together in sequence and offset by a fixed slot pitch according to winding rules. They are then wound into a coil with a set number of slots using a tooling fixture, and finally pushed into the stator through the stator slot opening to form a wound coil. For example... Figure 12 and Figure 13 As shown, in one embodiment, the flat wire wave winding 10 of the present invention may be composed of a plurality of first shaped conductors 30, a plurality of second shaped conductors 60, a plurality of third shaped conductors 80, and a plurality of fourth shaped conductors 100. Figure 12 and Figure 13 As shown, in terms of process, the first forming wire 30 and the second forming wire 60 can be regarded as a first pair of forming wires 120; while the third forming wire 80 and the fourth forming wire 100 can be regarded as a second pair of forming wires 130. During manufacturing, a plurality of first pairs of forming wires 120 and a plurality of second pairs of forming wires 130 can be stacked together in sequence and offset by a fixed slot pitch according to the winding rules; then, they are wound into a coil with a set number of slots in a tooling, and finally pushed into the stator from the stator slot opening end to form a winding. In the above embodiment of the 48-slot three-phase motor, the flat wire wave winding 10 is composed of 12 pairs of forming wires (6 of each of the four types of forming wires), each wire is stacked and offset by a slot pitch, and then wound and pushed into the stator.

[0048] The flat wire wave winding 10 of this invention is suitable for multi-phase motors containing multi-phase currents. Taking a three-phase motor as an example, the winding structure of the flat wire wave winding 10 of this invention consists of multiple coils forming U-phase, V-phase, and W-phase windings, allowing U-phase current, V-phase current, and W-phase current to flow into them respectively. The following will use the U-phase winding as an example to illustrate the coil winding configuration of the flat wire wave winding 10 of this invention. Figure 15 and Figure 16 As shown, in one embodiment, the U-phase winding includes a first coil U1, a second coil U2, a third coil U3, and a fourth coil U4. These four coils can be connected in parallel or series as needed to form one, two, or four branches of the U-phase winding. The configuration methods of each coil in the stator are described in detail below.

[0049] Reference Figure 14A and Figure 14B . Figure 14A This is a schematic diagram of the unfolded first coil U1, and... Figure 14B This is a schematic diagram of the structure of the first coil U1 in the stator. According to an embodiment of the present invention, the first coil U1 may be composed of a first shaped wire 30 and a third shaped wire 80. The first shaped wire 30 is a coil extending from the outermost layer of the wire layer inwards, while the third shaped wire 80 is a coil extending from the innermost layer of the wire layer inwards. The structures of the first shaped wire 30 and the third shaped wire 80 have been previously described and will not be repeated here. The first coil U1 can be formed by welding the two connecting ends 350 and 850 of the two shaped wires. In this embodiment, the first coil U1 occupies a total of 32 specific wire layer positions in specific stator slots, forming part of the flat wire wave winding 10 structure of the present invention.

[0050] Figure 15 This is a schematic diagram of the second coil U2. According to one embodiment, the second coil U2 is composed of a second shaped conductor 60 and a fourth shaped conductor 100. The second shaped conductor 60 is a coil extending from the outermost layer of the conductor layer inwards, while the fourth shaped conductor 100 is a coil extending from the innermost layer of the conductor layer inwards. The structures of the second shaped conductor 60 and the fourth shaped conductor 100 have been previously described and will not be repeated here. The second coil U2 is formed by welding the two connecting ends 650 and 1050 of the two shaped conductors together. In this embodiment, the second coil U2 occupies a total of 32 specific conductor layer positions in specific stator slots, forming part of the flat wire wave winding 10 structure of the present invention.

[0051] Furthermore, the structure of the third coil U3 is similar to that of the first coil U1, consisting of a first shaped wire 30 and a third shaped wire 80, which will not be described in detail here. The fourth coil U4 is similar to the second coil U2, consisting of a second shaped wire 60 and a fourth shaped wire 100, which will not be described in detail here.

[0052] Please refer to Figure 16 as well as Figure 17 . Figure 16 This is an embodiment of the winding structure of the flat wire wave winding 10 of the present invention. Figure 17 This is another embodiment of the winding structure of the flat wire wave winding 10 of the present invention. To clearly illustrate the position of the flat wire wave winding 10 in the stator slots and conductor layer, the following example uses the U-phase winding of a three-phase motor with 48 stator slots as an example. Figure 16 The example illustrates this.

[0053] Please refer to Figure 14A and Figure 16 As described above, the first coil U1 in this embodiment is composed of a first shaped conductor 30 and a third shaped conductor 80. The first shaped conductor 30 is a coil extending from the outermost layer of the conductor layer inwards, while the third shaped conductor 80 is a coil extending from the innermost layer of the conductor layer outwards. Figure 16 As shown, the lead-out section 301 of the first formed conductor 30 occupies the outermost conductor layer position of the third stator slot (3#L1), the connecting section 316 occupies the innermost conductor layer position of the 47th stator slot near the stator slot opening (47#L8), and the straight sections 302-315 in the middle occupy specific stator slots and conductor layer positions in sequence. Additionally, as... Figure 16 As shown, the connecting section conductor 816 of the third formed conductor 80 occupies the conductor layer position (5#L8) of the innermost ring of the 5th stator slot, closest to the stator slot opening, while the lead-out section conductor 801 occupies the conductor layer position (9#L1) of the outermost ring of the 9th stator slot; similarly, the straight sections conductors 802 to 815 in the middle occupy specific stator slots and conductor layer positions in sequence. Specifically, as... Figure 16 As shown, the first coil U1 can be configured in the stator structure as follows: 3#L1 - 10#L2 - 15#L2 - 22#L2 - 27#L3 - 34#L4 - 39#L4 - 46#L4 - 4#L5 -11#L6 - 16#L6 - 23#L6 - 28#L7 - 35#L8 - 40#L8 - 47#L8 - 5#L8 - 46#L7 - 41#L7-34#L7 - 29#L6 - 22#L5 - 17#L5 - 10#L5 - 4#L4 - 45#L3 - 40#L3 - 33#L3 - 28#L2- 21#L1 - 16#L1 - 9#L1.

[0054] Please refer to Figure 15 and Figure 16As described above, the second coil U2 in this embodiment is composed of a second shaped conductor 60 and a fourth shaped conductor 100. The second shaped conductor 60 is a coil extending from the outermost layer of the conductor layer inwards, while the fourth shaped conductor 100 is a coil extending from the innermost layer of the conductor layer outwards. Figure 16 As shown, the lead-out section 601 of the second formed conductor 60 occupies the outermost conductor layer position of the 4th stator slot (4#L1), the connecting section 616 occupies the innermost conductor layer position of the 46th stator slot near the stator slot opening (46#L8), while the straight sections 602-615 in the middle occupy specific stator slots and conductor layer positions in sequence. Furthermore, by... Figure 15 As shown, the connecting section conductor 1016 of the fourth forming conductor 100 occupies the conductor layer position (4#L8) of the innermost ring of the fourth stator slot near the stator slot opening, while the lead-out section conductor 1001 occupies the conductor layer position (10#L1) of the outermost ring of the tenth stator slot; similarly, the straight section conductors 1002 to 1015 in the middle occupy specific stator slots and conductor layer positions in sequence. Specifically, as... Figure 16 As shown, the second coil U2 can be configured in the stator structure as follows: 4#L1 - 9#L2 - 16#L2 - 21#L2 - 28#L3 - 33#L4 - 40#L4 - 45#L4 - 5#L5 -10#L6 - 17#L6 - 22#L6 - 29#L7 - 34#L8 - 41#L8 - 46#L8 - 4#L8 - 47#-L7 - 40#L7- 35#L7- 28#L6 - 23#L5 - 16#L5 - 11#L5 - 3#L4 - 46#L3 - 39#L3 - 34#L3 - 27#L2- 22#L1 - 15#L1 - 10#L1.

[0055] Similar to the first coil U1, the third coil U3 in this embodiment is also composed of a first shaped wire 30 and a third shaped wire 80 (schematic diagram omitted). The first shaped wire 30 is a coil extending from the outermost layer of the wire layer inwards, while the third shaped wire 80 is a coil extending from the innermost layer of the wire layer outwards. Figure 16 As shown, the lead-out section 301 of the first formed conductor 30 occupies the outermost conductor layer position of the 27th stator slot (27#L1), the connecting section 316 occupies the innermost conductor layer position of the 23rd stator slot near the stator slot opening (23#L8), while the straight sections 302-315 in the middle occupy specific stator slots and conductor layer positions in sequence. Furthermore, by... Figure 16As shown, the connecting section conductor 816 of the third formed conductor 80 occupies the conductor layer position (29#L8) of the innermost ring of the 29th stator slot, closest to the stator slot opening, while the lead-out section conductor 801 occupies the conductor layer position (33#L1) of the outermost ring of the 33rd stator slot; similarly, the straight sections conductors 802-815 in the middle occupy specific stator slots and conductor layer positions in sequence. Specifically, as... Figure 16 As shown, the third coil U3 can be configured in the stator structure as follows: 27#L1 - 34#L2 - 39#L2 - 46#L2 - 3#L3 - 10#L4 - 15#L4 - 22#L4 - 28#L5- 35#L6 - 40#L6 - 47#L6 - 4#L7 - 11#L8 - 16#L8 - 23#L8 - 29#L8 - 22#L7 - 17#L7 -10#L7 - 5#L6 - 46#L5 - 41#L5 - 34#L5 - 28#L4 - 21#L3 - 16#L3 - 9#L3 - 4#L2 - 45#L1 - 40#L1 - 33#L1.

[0056] Similar to the second coil U2, the fourth coil U4 in this embodiment is also composed of a second shaped conductor 60 and a fourth shaped conductor 100 (schematic diagram omitted). The second shaped conductor 60 is a coil extending from the outermost layer of the conductor layer inwards, while the fourth shaped conductor 100 is a coil extending from the innermost layer of the conductor layer outwards. Figure 16 As shown, the lead-out section 601 of the second formed conductor 60 occupies the outermost conductor layer position of the 28th stator slot (28#L1), the connecting section 616 occupies the innermost conductor layer position of the 22nd stator slot near the stator slot opening (22#L8), and the straight sections 602-615 in the middle occupy specific stator slots and conductor layer positions in sequence. Additionally, as... Figure 16 As shown, the connecting section conductor 1016 of the fourth forming conductor 100 occupies the conductor layer position (28#L8) of the innermost ring of the 28th stator slot, near the stator slot opening, while the lead-out section conductor 1001 occupies the conductor layer position (34#L1) of the outermost ring of the 34th stator slot; similarly, the straight section conductors 1002 to 1015 in the middle occupy specific stator slots and conductor layer positions in sequence. Specifically, as... Figure 16 As shown, the fourth coil U4 can be configured in the stator structure as follows: 28#L1 - 33#L2 - 40#L2 - 45#L2 - 4#L3 - 9#L4 - 16#L4 - 21#L4 - 29#L5 -34#L6 - 41#L6 - 46#L6 - 5#L7 - 10#L8 - 17#L8 - 22#L8 - 28#L8 - 23#L7 - 16#L7-11#L7 - 4#L6 - 47#L5 - 40#L5 - 35#L5 - 27#L4 - 22#L3 - 15#L3 - 10#L3 - 3#L2- 46#L1 - 39#L1 - 34#L1.

[0057] Comparing the structural configurations of the first coil U1 and the third coil U3 in the stator reveals that the third coil U3 is configured by offsetting the first coil U1 by 24 stator slots (i.e., the number of stator slots / 2). In other words, the coil shape of the third coil U3 is essentially the same as that of the first coil U1, except that the stator slot positions occupied by each straight conductor of the third coil U3 and the first coil U1 are 24 slot pitches apart. Similarly, comparing the structural configurations of the second coil U2 and the fourth coil U4 in the stator reveals that the fourth coil U4 is configured by offsetting the second coil U2 by 24 stator slots (i.e., the number of stator slots / 2). In other words, the coil shape of the fourth coil U4 is essentially the same as that of the second coil U2, except that the stator slot positions occupied by each straight conductor of the fourth coil U4 and the second coil U2 are 24 slot pitches apart. In terms of manufacturing, only multiple sets of these two coils are needed to complete the structure of the flat wire wave winding 10 of this invention.

[0058] according to Figure 16 The coil span rule of the flat wire 10 of this invention maintains approximately three different variations with respect to the pole pitch D: (1) The sections of two adjacent straight conductors alternately change between a first span and a second span; (2) When encountering the central bridging section of a shaped conductor, the span between the two connected straight conductors is adjusted to a third span. (3) When one shaped conductor is connected to another shaped conductor, the span between the two connecting conductors is adjusted to a fourth span.

[0059] In one embodiment, for the first coil U1 and the third coil U3, the first span is equal to the pole pitch D+1, and the second span is equal to the pole pitch D-1; furthermore, the third span and the fourth span are equal, both equal to the pole pitch D. In another embodiment, for the second coil U2 and the fourth coil U4, the first span is equal to the pole pitch D-1, the second span is equal to the pole pitch D+1, the third span is equal to the pole pitch D+2, and the fourth span is equal to the pole pitch D.

[0060] Specifically, taking the aforementioned 48 stator slots as an example, assume the pole pitch D equals 6. (Refer to...) Figure 14A and Figure 16 The span between the first coil U1 and its adjacent straight conductor sections generally maintains an alternating pattern of 7 slot pitches (i.e., the first span) and 5 slot pitches (i.e., the second span). For example, as shown in the figure, the span between the lead-out conductor 301 and the straight conductor 302 is 7 slot pitches, the span between the straight conductor 302 and the straight conductor 303 is 5 slot pitches, the span between the straight conductor 303 and the straight conductor 304 is 7 slot pitches, and so on. However, when encountering the central bridging section of the formed conductor, the span is adjusted to 6 slot pitches (i.e., the third span). For example, the span between the two adjacent straight conductor sections 308 and 309 connected by the central bridging section 408 of the first formed conductor 30 is adjusted to 6 slot pitches; that is, when the first coil U1 crosses from the fourth conductor layer (46#L4) of slot 46 to the fifth conductor layer (4#L5) of slot 4, the span is adjusted to 6 slot pitches. Similarly, the span between the two straight conductor segments 808 and 809 connected by the central bridging portion 908 of the third shaped conductor 80 will also be adjusted to 6 slot pitches; that is, when the first coil U1 crosses from the fifth conductive layer (10#L5) of the 10th slot to the fourth conductive layer (4#L4) of the 4th slot. Furthermore, when two shaped conductors are connected, the span will be adjusted to 6 slot pitches (i.e., the fourth span). For example, the span between the connecting segment conductor 316 of the first shaped conductor 30 and the connecting segment conductor 816 of the third shaped conductor 80 changes to 6 slot pitches; that is, when the first coil U1 crosses from the eighth conductor layer (47#L8) of the 47th slot to the eighth conductor layer (5#L8) of the 5th slot.

[0061] Similarly, refer to Figure 16 The span of the third coil U3 and its adjacent straight conductor is the same as that of the first winding U1, roughly maintaining an alternating pattern of 7 slot pitches (i.e., the first span) and 5 slot pitches (i.e., the second span). However, when encountering the central bridging section of the shaped conductor, the span is adjusted to 6 slot pitches (i.e., the third span); and when two shaped conductors are connected, the span is also adjusted to 6 slot pitches (i.e., the fourth span). Specifically, when encountering the central bridging section of the shaped conductor, that is, when the third coil U3 crosses from the fourth conductor layer (22#L4) of slot 22 to the fifth conductor layer (28#L5) of slot 28, and when the third coil U3 crosses from the fifth conductive layer (34#L5) of slot 34 to the fourth conductive layer (28#L4) of slot 28, the span is adjusted to 6 slot pitches. In addition, when the two shaped conductors are connected, that is, when the third coil U3 crosses from the eighth conductor layer of slot 23 (23#L8) to the eighth conductor layer of slot 29 (29#L8), the span is adjusted to 6 slots.

[0062] like Figure 14A and Figure 16As shown, the three different span configuration methods make the two lead-out sections 301 and 801 of the first coil U1 maintain a distance of 6 slot pitches, and the first forming wire 30 and the third forming wire 80 are aligned in the middle of the winding, that is, the central position of the two forming wires is in the adjacent wire layer position (i.e., the 4th layer and the 5th layer) of the same stator slot (note the 4th stator slot), while the other positions maintain an offset of one stator slot.

[0063] Similarly, the third winding U3 is in the same situation.

[0064] Furthermore, taking the aforementioned 48 stator slots as an example, assume the pole pitch D equals 6. (Refer to...) Figure 15 and Figure 16 The span between the second coil U2 and the adjacent straight conductor section generally maintains an alternating pattern of 5 slot pitches (i.e., the first span) and 7 slot pitches (i.e., the second span). For example, as shown in the figure, the span between the lead-out conductor 601 and the straight conductor 602 is 5 slot pitches, the span between the straight conductor 602 and the straight conductor 603 is 7 slot pitches, the span between the straight conductor 603 and the straight conductor 604 is 5 slot pitches, and so on. However, when encountering the central bridging section of the formed conductor, the span is adjusted to 8 slot pitches (i.e., the third span). For example, the span between the two adjacent straight conductor sections 608 and 609 connected by the central bridging section 708 of the second formed conductor 60 is adjusted to 8 slot pitches; that is, when the second coil U2 crosses from the fourth conductor layer (45#L4) of slot 45 to the fifth conductor layer (5#L5) of slot 5. Similarly, the span between the two straight conductor segments 1008 and 1009 connected by the central bridging portion 1108 of the fourth shaped conductor 100 will also be adjusted to 8 slot pitches; that is, when the second coil U2 crosses from the fifth conductive layer (11#L5) of the 11th slot to the fourth conductive layer (3#L4) of the 3rd slot. Furthermore, when two shaped conductors are connected, the span will be adjusted to 6 slot pitches (i.e., the fourth span). For example, the span between the connecting segment conductor 616 of the second shaped conductor 60 and the connecting segment conductor 1016 of the fourth shaped conductor 100 will be adjusted to 6 slot pitches; that is, when the second coil U2 crosses from the eighth conductor layer (46#L8) of the 46th slot to the eighth conductor layer (4#L8) of the 4th slot.

[0065] Similarly, refer to Figure 16The span of the fourth coil U4 and its adjacent straight conductor is the same as that of the second coil U2, roughly maintaining an alternating pattern of 5 slot pitches (i.e., the first span) and 7 slot pitches (i.e., the second span). However, when encountering the central bridging section of the shaped conductor, the span is adjusted to 8 slot pitches (i.e., the third span); and when two shaped conductors are connected, the span is also adjusted to 6 slot pitches (i.e., the fourth span). Specifically, when encountering the central bridging section of the shaped conductor, that is, when the fourth coil U4 crosses from the fourth conductor layer of slot 21 (21#L4) to the fifth conductor layer of slot 29 (29#L5), and when the fourth coil U4 crosses from the fifth conductive layer of slot 35 (35#L5) to the fourth conductive layer of slot 27 (27#L4), the span is adjusted to 8 slot pitches. In addition, when the two shaped conductors are connected, that is, when the fourth coil U4 crosses from the eighth conductor layer of slot 22 (22#L8) to the eighth conductor layer of slot 28 (28#L8), the span is adjusted to 6 slots.

[0066] like Figure 15 and Figure 16 As shown, the four different span configurations ensure that the two lead-out sections 601 and 1001 of the second coil U2 maintain a distance of 6 slot pitches, and the second forming conductor 60 and the fourth forming conductor 100 differ by 2 slot pitches in the middle of the winding. That is, the central straight sections 609 and 1009 of the two forming conductors are located in the adjacent conductor layers of the 5th and 3rd stator slots, respectively (i.e., the 5th and 4th layers), while the remaining positions maintain an offset of one stator slot. Similarly, the fourth winding U4 follows the same pattern.

[0067] According to another embodiment of the present invention, referring to Figure 17 In this invention, the flat wire wave winding 10 can also remain unchanged in span, only changing sequentially according to a first span (i.e., pole pitch D+1) and a second span (i.e., pole pitch D-1). Specifically, as... Figure 17 As shown, the span between two adjacent straight conductor sections of the first coil U1 and the third coil U3 alternates between 7 slot pitches and 5 slot pitches. Similarly, the span between two adjacent straight conductor sections of the second coil U2 and the fourth coil U4 alternates between 5 slot pitches and 7 slot pitches.

[0068] In addition to the span rule, the span between two adjacent straight conductor portions in the flat wire wave winding 10 of the present invention is also maintained at no more than one conductor layer. As described above, the flat wire wave winding 10 is composed of a plurality of coils, and each coil is composed of at least one shaped conductor. When the shaped conductor is a coil extending from the outer layer of the conductor layer inward (e.g., the first shaped conductor 30 of the first coil U1), the straight conductor portion of the shaped conductor stays only once in all odd-numbered conductive layers, and the remaining straight conductor portions occupy all even-numbered layers on an average basis; in addition, when the shaped conductor is a coil extending from the inner layer of the conductor layer outward (e.g., the third shaped conductor 80 of the first coil U1), the straight conductor portion of the shaped conductor stays only once in all even-numbered conductive layers, and the remaining straight conductor portions occupy all odd-numbered layers on an average basis.

[0069] Taking the aforementioned 48 stator slots as an example, refer to Figure 14A and Figure 16 The first shaped conductor 30 of the first coil U1 is a coil extending from the outer layer of the conductor layer inwards. Therefore, the straight conductor portions 301 to 316 of the first shaped conductor 30 only stop once when passing through odd-numbered conductor layers, with the remainder evenly distributed in all even-numbered conductor layers. Specifically, straight conductor portions 301, 305, 309, and 313 occupy odd-numbered conductor layers L1, L3, L5, and L7 respectively, while straight conductors 302 to 304, 306 to 308, 310 to 312, and 314 to 316 occupy even-numbered conductor layers L2, L4, L6, and L8 respectively. Conversely, the third shaped conductor 80 of the first coil U1 is a coil extending from the inner layer of the conductor layer outwards. Therefore, the straight conductor portions 801 to 816 of the third shaped conductor 80 only stop once when passing through even-numbered conductor layers, with the remainder evenly distributed in all odd-numbered conductor layers. Specifically, straight conductors 816, 812, 808, and 804 occupy even-numbered conductor layers L8, L6, L4, and L2, respectively, while straight conductors 813–815, 809–811, 805–807, and 801–803 occupy odd-numbered conductor layers L7, L5, L3, and L1, respectively. The winding rules for the second coil U2, the third coil U3, and the fourth coil U4 are the same as those for the first coil U1, and will not be repeated here.

[0070] The first coil U1, the second coil U2, the third coil U3, and the fourth coil U4 constitute the U-phase winding of the flat wire wave winding 10. The V-phase winding and W-phase winding structures of the present invention are generally similar to the U-phase winding, but they occupy stator slots offset by two stator slot positions respectively. For example, in various span variations, the U-phase windings sequentially occupy stator slots 3#-5#, 9#-11#, 15#-17#, 21#-23#, 27#-29#, 33#-35#, 39#-41#, and 45#-47#; the V-phase windings sequentially occupy slots 5#-7#, 11#-13#, 17#-19#, 23#-25#, 29#-31#, 35#-37#, 41#-43#, and 47#-1#; and the W-phase windings sequentially occupy slots 7#-9#, 13#-15#, 19#-21#, 25#-27#, 31#-33#, 37#-39#, 43#-45#, and 1#-3#. Similarly, those familiar with the technology can further deduce the stator slots occupied by the U-phase, V-phase, and W-phase windings when the span has only two variations. For example... Figure 16 and Figure 17 As shown, regardless of the winding rule, for a three-phase motor with 48 stator slots, the flat wire wave winding 10 requires a total of 24 shaped conductors (3 phases * 4 windings * 2 shaped conductors) to fill all stator slots.

[0071] The flat wire wave winding disclosed in this invention is applicable to an M-phase motor. The M-phase motor includes 2*n stator slots, each stator slot defining 2*k conductor layer positions, with p pole pairs and D pole pitch; where 2*k is an even number not less than 4, and M is a positive integer. The flat wire wave winding of this embodiment includes M phase windings, each phase winding containing a plurality of coils. Each coil is composed of at least one shaped conductor, which includes a plurality of straight conductor segments and a plurality of bridging portions connecting adjacent straight conductor segments. The total number I of straight conductor segments in the shaped conductor can be set as: I = number of stator slots 2*n / number of motor phases M; and the total number of bridging portions J is: J = number of straight conductor segments I - 1.

[0072] In one embodiment, the shaped conductor includes at least a first shaped conductor and a second shaped conductor. The straight conductor portions of the first and second shaped conductors each include a lead-out section, a connecting section, and a plurality of straight conductor segments. Furthermore, each lead-out section includes a lead-out end, and each connecting section includes a connecting end.

[0073] The structural shapes of the first and second shaped conductors of the present invention, and the winding rules of the flat-wave winding are as follows: Rule 1: The adjacent straight conductor sections of the first formed conductor maintain the alternating change of the first span and the second span in turn; Rule 2: The adjacent straight conductor sections of the second shaped conductor maintain the alternating change of the second span and the first span in turn; Rule 3: Regardless of whether it is the first or second shaped conductor, when encountering the central bridging section, the span of the two connected straight conductors shall be adjusted to the third span. Rule 4: Regardless of whether it is the first or second shaped conductor, when two shaped conductors are connected, the span between the two connecting segments is adjusted to the fourth span.

[0074] Specifically, the first span is equal to the pole pitch D+1 of the M-phase motor, the second span is equal to the pole pitch D-1 of the M-phase motor, and the fourth span is equal to the pole pitch D of the M-phase motor. Furthermore, for the first formed conductor, the third span is also equal to the pole pitch D of the M-phase motor; however, for the second formed conductor, the third span is equal to the pole pitch D+2 of the M-phase motor.

[0075] In another embodiment, the above-mentioned winding rules three and four are selective rules.

[0076] In another embodiment, the flat wire wave winding of the present invention further comprises a plurality of coils forming a phase winding, each coil consisting of at least two shaped conductors. The first shaped conductor is a coil extending from the outermost conductor layer of the stator towards the innermost coil near the stator slot opening, and the second shaped conductor is a coil extending from the innermost conductor layer of the stator towards the outermost coil. The two shaped conductors are bent together at one end and then welded together. The winding rules of the flat wire wave winding of the present invention further include the following: Rule 5: The straight conductor portion of the first formed conductor stays only once in odd-numbered conductor layers, while the remaining straight conductor portions are distributed evenly across all even-numbered conductor layers; and Rule 6: The straight conductor portion of the second formed conductor stays only once in even-numbered conductor layers, while the remaining straight conductor portions are distributed evenly in all odd-numbered conductor layers.

[0077] In another embodiment, the plurality of coils of the flat wire wave winding of the present invention can be further classified into first coils and second coils; the flat wire wave winding of the present invention is composed of a plurality of first coils and a plurality of second coils. Each first coil may consist of two first shaped conductors; the first first shaped conductor is a coil extending from the outermost conductor layer of the stator towards the innermost ring near the stator slot opening, and the second first shaped conductor is a coil extending from the innermost conductor layer of the stator towards the outermost ring. The two first shaped conductors are bent together at one end and then welded together. Similarly, each second coil may consist of two second shaped conductors; the first second shaped conductor is a coil extending from the outermost conductor layer of the stator towards the innermost ring near the stator slot opening, and the second second shaped conductor is a coil extending from the innermost conductor layer of the stator towards the outermost ring. The two second shaped conductors are bent together at one end and then welded together. The first coils and second coils form phase windings in the stator according to rules one to six described above.

[0078] Furthermore, the winding rules for the flat wire wave winding of the present invention further include the following: Rule 7: The stator slot positions occupied by the straight conductor portions of one first coil and another first coil differ by half the total number of stator slots; and the stator slot positions occupied by the straight conductor portions of one second coil and another second coil differ by half the total number of stator slots.

[0079] In another embodiment, for ease of manufacturing, the conductors required to form the flat wire wave winding of the present invention can be made into the required shape, reducing the bending required during welding. Specifically, the shaped conductors required for the flat wire wave winding of the present invention may further include a first shaped conductor, a second shaped conductor, a third shaped conductor, and a fourth shaped conductor. The third shaped conductor is approximately the same shape as the first shaped conductor, and the straight conductor portion also follows the span rules of rules one to four described above. However, the bending directions of the connection ends of the third shaped conductor and the first shaped conductor are opposite. For example, the connection end of the first shaped conductor is bent in the direction opposite to the lead-out end, while the connection end of the third shaped conductor is bent towards the lead-out end. Similarly, the fourth shaped conductor is approximately the same shape as the second shaped conductor, and the straight conductor portion also follows the span rules of rules one to four described above. However, the bending directions of the connection ends of the fourth shaped conductor and the second shaped conductor are opposite. For example, the connection end of the second shaped conductor is bent in the direction opposite to the lead-out end, while the connection end of the fourth shaped conductor is bent towards the lead-out end. Because the process has already prefabricated the required bends in the connecting ends of the shaped wires, the first coil can be formed by directly welding the connecting ends of the first and third shaped wires, and the second coil can be formed by directly welding the connecting ends of the second and fourth shaped wires. This reduces the bending steps during welding and minimizes damage.

[0080] Furthermore, the shapes of the first shaped conductor, the second shaped conductor, the third shaped conductor, and the fourth shaped conductor can be further varied as follows: (1) On the lead-out side, the bend of the central bridging section (i.e. the (J+1) / 2nd bridging section) can be adjusted to be offset by a first arc Q1 in the direction of the lead-out section conductor, where the first arc Q1 is: pi / (2*n); (2) On the non-lead side, the bends of the first two consecutive non-lead side bridging sections near the central bridging section (i.e. the [(J+1) / 2]-1 and [(J+1) / 2]-3 bridging sections) can be adjusted to be offset by a second arc Q2 in the direction of the connecting section conductor, where the second arc Q2 is: Q2 = pi / n; (3) Except for the above changes, the bends of the remaining bridging parts are all kept at the angle bisectors of the two adjacent straight line segments.

[0081] The bending changes at the bridging sections of the third and fourth shaped conductors are as follows: (1) On the lead-out side, the bend of the central bridging section (i.e. the (J+1) / 2nd bridging section) can be adjusted to be offset by a first arc Q1 in the direction of the lead-out section conductor, where the first arc Q1 is: Q1=pi / (2*n); (2) On the lead-out side, the bend of the next lead-out side bridging part (i.e. the [ (J+1) / 2]+2 bridging part) of the central bridging part can be adjusted to be offset by a second arc Q2 in the direction of the lead-out section conductor, where the second arc Q2 is: Q2=pi / n; (3) On the non-lead side, the bend of the previous non-lead side end bridging part (i.e. the [ (J+1) / 2]-1 bridging part) near the central bridging part can be adjusted to be offset by a second arc Q2 in the direction of the connecting section conductor, where the second arc Q2 is: Q2= pi / n; (4) Except for the above changes, the bends of the remaining bridging parts are all kept at the angle bisectors of the two adjacent straight line segments.

[0082] Where pi is the mathematical constant π.

[0083] In this embodiment, each first coil may consist of a first shaped conductor and a third shaped conductor, while each second coil may consist of a second shaped conductor and a fourth shaped conductor. A plurality of first coils and a plurality of second coils are arranged in the stator to form phase windings according to the configuration methods described in Rules 5 to 7 above.

[0084] In summary, the flat wire corrugated coil of the present invention is formed by simply winding shaped wire, making its manufacturing and process simpler than existing corrugated coils. By forming the wire in one step, 90% of the winding welding points are saved, thus reducing the amount of motor wire used. Furthermore, the flat wire corrugated coil of the present invention can employ a long-pitch design to weaken tooth harmonics and improve NVH (noise, vibration, and harshness), and can also employ a positional pitch design to increase torque. Therefore, the flat wire corrugated coil of the present invention can significantly reduce the risky operations of cutting, bending, and welding wires required in existing flat wire winding coils.

[0085] The above description is only a preferred embodiment of the present invention. All equivalent changes and modifications made in accordance with the claims of the present invention should be included within the scope of the present invention.

Claims

1. A flat wire corrugated winding for a multiphase motor having a single pole pitch, the flat wire corrugated winding comprising: A first shaped conductor, a second shaped conductor, a third shaped conductor, and a fourth shaped conductor; in, The first molded conductor, the second molded conductor, the third molded conductor, and the fourth molded conductor are all integrally molded conductors and each includes a plurality of straight conductor portions and a plurality of bridging portions. The plurality of bridging portions are used to connect two adjacent straight conductor portions. The span between two adjacent straight conductor portions of the first and third shaped conductors alternately maintains a first span and a second span; and The span between two adjacent straight conductor portions of the second and fourth shaped conductors alternately changes between the second span and the first span. The multiphase motor includes a stator, the stator includes a plurality of stator slots, one side of the stator is a lead-out side and the other side is a non-lead-out side; The straight conductor portions of the first shaped conductor, the second shaped conductor, the third shaped conductor, and the fourth shaped conductor each include a lead-out conductor, a connecting conductor, and a plurality of straight conductor segments. The bending of the bridging portion of the first and second molded conductors respectively includes: On the lead-out side, the bend of the central bridging portion is offset by a first arc in the direction of the lead-out section conductor; The bends of the two consecutive bridging sections on the non-lead-out side before the central bridging section are offset by a second arc in the direction of the connecting section conductor. as well as The bends of the remaining bridging portions remain at the angle bisectors of the two adjacent straight segments.

2. The flat wire winding as claimed in claim 1, wherein the first span is equal to the pole pitch plus one, and the second span is equal to the pole pitch minus one.

3. The flat wire winding as described in claim 1, wherein the span between two adjacent straight conductor portions connected by the central bridging portion of the first shaped conductor, the second shaped conductor, the third shaped conductor, and the fourth shaped conductor is adjusted to a third span.

4. The flat wire winding as claimed in claim 3, wherein the third span of the first shaped conductor and the third shaped conductor is equal to the pole pitch, and the third span of the second shaped conductor and the fourth shaped conductor is equal to the pole pitch plus two.

5. The flat wire winding as claimed in claim 1, wherein the straight conductor portion of the first shaped conductor, the second shaped conductor, the third shaped conductor, and the fourth shaped conductor each includes a connecting section conductor, wherein when the first shaped conductor and the third shaped conductor are connected through their respective connecting section conductors, and when the second shaped conductor and the fourth shaped conductor are connected through their respective connecting section conductors, the span between the two connecting section conductors is a fourth span.

6. The flat wave winding as described in claim 5, wherein the fourth span is equal to the pole pitch.

7. The flat wire winding as claimed in claim 1, wherein some of the bridging portions of the first shaped conductor, the second shaped conductor, the third shaped conductor, and the fourth shaped conductor are located on the lead-out side, and some are located on the non-lead-out side; the number of straight conductor portions of the first shaped conductor, the second shaped conductor, the third shaped conductor, and the fourth shaped conductor is the number of stator slots divided by the number of phases of the multiphase motor, and the number of bridging portions is the number of straight conductors minus one.

8. The flat wire winding as claimed in claim 7, wherein the lead-out section conductor includes a lead-out end, the connecting section conductor includes a connecting end, and both the lead-out end and the connecting end are located on the lead-out side.

9. The flat wave winding as described in claim 8, wherein: The bending of the bridging portion of the third and fourth shaped conductors respectively includes: On the lead-out side, the bend of the central bridging portion is offset by the first arc in the direction of the lead-out section conductor; On the lead-out side, the bend of the next bridging portion of the central bridging portion is offset by the second arc in the direction of the lead-out section conductor; The bend of one of the bridging portions on the non-lead-out side near the central bridging portion is offset by the second arc in the direction of the connecting segment conductor; as well as The bends of the remaining bridging portions remain at the angle bisectors of the two adjacent straight segments.

10. The flat wire wave winding as claimed in claim 9, wherein the first radian is pi divided by the total number of stator slots, and the second radian is pi divided by half the total number of stator slots.

11. The flat wire corrugated winding as claimed in claim 1, wherein the flat wire corrugated winding further comprises: A first coil and a third coil are respectively composed of the first shaped wire and the third shaped wire; as well as A second coil and a fourth coil are respectively composed of the second shaped wire and the fourth shaped wire; The first coil, the second coil, the third coil, and the fourth coil together form one phase winding of the flat wire.

12. A multiphase motor having a pole pitch, the multiphase motor comprising: A stator includes a plurality of stator slots, wherein one side of the stator is a lead-out side and the other side is a non-lead-out side; A rotor containing a complex number of pole pairs; and A flat-wire corrugated wire is disposed in the stator, wherein the flat-wire corrugated wire comprises: A first shaped conductor, a second shaped conductor, a third shaped conductor, and a fourth shaped conductor; in, The first shaped conductor, the second shaped conductor, the third shaped conductor and the fourth shaped conductor each include a plurality of straight conductor portions that occupy the stator slots in sequence and a plurality of bridging portions used to connect two adjacent straight conductor portions; Each of the plurality of straight conductor portions includes a lead-out conductor, a connecting conductor, and a plurality of straight conductor segments, wherein the lead-out conductor includes a lead-out end and the connecting conductor includes a connecting end. The lead-out end and the connection end are located on the lead-out side; Some of the plurality of bridging portions are located on the lead-out side, and some are located on the non-lead-out side; The span between two adjacent straight conductor portions of the first and third shaped conductors alternately maintains a first span and a second span; and The span between two adjacent straight conductor portions of the second and fourth shaped conductors alternately changes between the second span and the first span. The bending of the bridging portion of the first and second molded conductors respectively includes: On the lead-out side, the bend of the central bridging portion is offset by a first arc in the direction of the lead-out section conductor; The bends of the two consecutive bridging sections on the non-lead-out side before the central bridging section are offset by a second arc in the direction of the connecting section conductor. as well as The bends of the remaining bridging portions remain at the angle bisectors of the two adjacent straight segments.

13. The multiphase motor of claim 12, wherein the first span is equal to the pole pitch plus one, and the second span is equal to the pole pitch minus one.

14. The multiphase motor as claimed in claim 12, wherein the span between two adjacent straight conductor portions connected by the central bridging portion of the first shaped conductor, the second shaped conductor, the third shaped conductor, and the fourth shaped conductor is adjusted to a third span.

15. The multiphase motor of claim 14, wherein the third span of the first shaped conductor and the third shaped conductor is equal to the pole pitch, and the third span of the second shaped conductor and the fourth shaped conductor is equal to the pole pitch plus two.

16. The multiphase motor of claim 12, wherein the first shaped conductor and the third shaped conductor are bent and welded together to form a coil, and the second shaped conductor and the fourth shaped conductor are bent and welded together to form another coil, wherein the span between the two connecting sections of the first shaped conductor and the third shaped conductor and the span between the two connecting sections of the second shaped conductor and the fourth shaped conductor is a fourth span.

17. The multiphase motor of claim 16, wherein the fourth span is equal to the pole pitch.

18. The multiphase motor as described in claim 12, wherein: The bending of the bridging portion of the third and fourth shaped conductors respectively includes: On the lead-out side, the bend of the central bridging portion is offset by the first arc in the direction of the lead-out section conductor; On the lead-out side, the bend of the next bridging portion of the central bridging portion is offset by the second arc in the direction of the lead-out section conductor; The bend of one of the bridging portions on the non-lead-out side near the central bridging portion is offset by the second arc in the direction of the connecting segment conductor; as well as The bends of the remaining bridging portions remain at the angle bisectors of the two adjacent straight segments.

19. The multiphase motor of claim 18, wherein the first radian is pi divided by the total number of stator slots, and the second radian is pi divided by half the total number of stator slots.

20. The multiphase motor of claim 12, wherein the flat wire winding further comprises: A first coil and a third coil are respectively composed of the first shaped wire and the third shaped wire; as well as A second coil and a fourth coil are respectively composed of the second shaped wire and the fourth shaped wire; The first coil, the second coil, the third coil, and the fourth coil together form one phase winding of the flat wire.

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